ed ZORA MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No INDIAL UMITED ‘CARBON STEEL COMPONENTS USED IN ceremony SOUR SERVICE FOR OIL & GAS 6-79-0012 Rev. 0 PRODUCTION Page 1 of 14 da we te sore & few ok afte a serra eM ot art Kiet saaat Vg are atten MATERIAL REQUIREMENTS FOR CARBON STEEL COMPONENTS USED IN SOUR SERVICE FOR OIL AND GAS PRODUCTION Rev. Rev. ate Purpose ‘Approved by Format No, 8-00-0001-F1 Rev. 0 Copyright EIL — Allights reservedSSHEIZTES iB ENGINEERS MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No, sawn OND UMITED cal znicies SIN \RBON STEEL COMPONENTS USED IN 6-79-0012 Rev. 0 Acer see ni ‘SOUR SERVICE FOR OIL & GAS. Page 2 of 14 PRODUCTION National Association of Corrosion Engineers International Organization for Standardization American Society for Testing and Materials American Petroleum Institute American Society for Mechanical Engineers ‘American National Standard Institute SMMS Standards Comt et Convenor: Sh. K.K. Mallick (SMMS) Members: Dr. G, Saha (SMMS) Dr. V.R. Krishnan (SMMS) Sh. P.P. Lahiri (SMMS) Sh. M.R. Chakraborty (Piping) Sh. A-K. Tandon (Construction) Dr. Mukesh Kumar (Metallurgy) Sh. S.K. Sood (Ref.1) Committee constituted to revise the standard: Chairman: Sh. B.K.Raut (SMMS) Members: Sh. B.S.Gupta (HMTD) Sh, G.D.Goyal (Process) Sh. M.R.Chakraborty (Piping) Sh. S.Yadav (Inspection) Format No, 6-00-0001-F1 Rev. 0 ‘Copyright EIL ~All ighis reserved~ SOmGRRTET Be ENGINEERS MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No. an AN LIMITED CARBON STEEL COMPONENTS USED IN SEIS Newnan ‘SOUR SERVICE FOR OIL & GAS 6-79-0012 Rev.0 PRODUCTION Page 3 of 14 CONTENTS SL PAGE NO. DESCRIPTION NO. 1.0 SCOPE 4 2.0 REFERENCE CODES/STANDARDS, 4 3.0 GENERAL REQUIREMENTS 4 4.0 | MATERIAL SPECIFICATION AND PRODUCTION TESTS 5 5.0 HARDNESS TEST 7 6.0 CORROSION TESTS 7 7.9 | QUALITY SURVEILLANCE AND INSPECTION DURING a “PRODUCTION 3,9 QUALIFICATION OF MANUFACTURERS / SUPPLIERS OF : SOUR SERVICE MATERIALS 9,9 SPECIAL REQUIREMENTS FOR WELDING AND FABRICATION a “© FOR SOUR SERVICE TABLE -1 TOV 12-14 Format No, 6-00-0007-F1 Rev. 0 Copyright IL —Alighis resewedSTANDARD SPECIFICATION No. sGileizr’ MATERIAL REQUIREMENTS FOR 6-79-0012 Rev. 0 ENGINEERS, SBT MERE NSAID canton steer ecoMreMeNTs USED IN ‘SOUR SERVICE FOR OIL. & GAS Page 4 of 14 PRODUCTION 1.0 SCOPE 1.1 This specification lays down the requirements related to the chemical composition, manufacture, fabrication and testing requirements for carbon steel components intended to be used in sour service environment. ‘These requirements are specified in order to. make the carbon steel component resistant to the various forms of material damage in a sour environment such as Sulfide Stress Cracking (SSC), Hydrogen Induced Cracking (HIC), Stress Oriented Hydrogen Induced Cracking (SOHIC), Blistering ete. These requirements. shall be used for resisting Alkaline Stress Corrosion Cracking (ASCC) also. This specification is applicable for offshore and onshore oil and gas production facilities. 1.2. The service medium is defined as “Sour” when the partial pressure of H2S in a wet (water as a liquid) gas phase of a gas, gas condensate or-crude oil system is equal to or exceeds 0.0003 MPa (0.05 Psia). 2.0 REFERENCED CODES / STANDARDS [ NACE MR 0175 /1SO 15156 | ASTM A 694 ASTM A770 NACE RP 0472 ASTM A 216 ASTMA370__ NACE TM 0177 ~ [ASTM A 106 ASTM A 578 NACE TM 0284 APISL ASME SEC II PART C ASTM A 20 ___[API6A ‘ASME SEC VIII-DIV.1 ASTM A S16 ASTME 18 ‘ASME SEC V & SEC IX ASTM A 105 ASTM E 45 ‘ANSI B 16.34 [ANSIB 31.3 All ASTM Standard designations shall be applicable for corresponding ASME designations which would be read as ASME SA XXX instead of ASTM A XXX. 3.0 GEI ;RAL REQUIREMENTS 3.1 The steel for sour service shall be manufactured by either basic oxygen or electric are furnace route and shall be fully killed and fine grained. 3.2 All, wrought products shall be produced and certified by the manufacturer as HIC resistant steel and shall be free of elongated inclusions. 3.3. Alll rolled products such as plates and HR coils used for components and equipments shall be of low sulfur and low phosphorus content, shall be vacuum degassed and calcium treated for sulfide shape control. 3.4 Plates shall be supplied in normalized, normalized and tempered or thermo- mechanically treated condition, unless otherwise agreed in writing, Format No, 6-00-0001-F1 Rev. 0 ‘Copyright GIL — Alvights reservedSoG ze > ENGINEERS MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No. s@arfcisits INDIA LIMITED CARBON STEEL COMPONENTS USED IN neers at etm ‘SOUR SERVICE FOR OIL & GAS er eoode eee D PRODUCTION Peco 3.5 Manufacturer shall take care to ensure that all products are free of low temperature transformation microstructures such as bainite bands or islets of martensite. 3.6 HIC test shall be conducted only for steel plates and products made out of, plates. 3.7 All items are required to conform to applicable material specification and chemical composition as detailed in Tables I to V. 4.0. MATERIAL SPECIFICATION AND PRODUCTION TEST! 4.1 Special Requirements 7 4.1.1 The various types of carbon steel sour service material component shall conform to the recommended product specifications and shall meet the additional requirements and modifications mentioned herein against each product specification. 4.1.2. The chemical composition analysis and mechanical tests shall be conducted for each heat and for each heat treatment batch of finished product in accordance with the respective product specifications and shall also meet the requirements mentioned in the various Tables referred to against each type of product. 4.1.3 The hardness testing shall be conducted on all products as mentioned in clause No.5.0 of this specification and shall meet the requirements laid down. 4.14 Corrosion tests, wherever specified against each type of product shall be conducted to meet the acceptance limits mentioned, unless specifically permitted otherwise in writing by the owner. 4.1.5 Non-Destructive Testing of the finished products shall be in accordance with the governing product specification and as modified in this specification in the corresponding clauses or as mentioned in any of the documents attached with MR 4.2 Product Specific Requirements 4.2.1 Seamless Pipes ASTM A 106 Gr. B and API SL Gr. B seamless pipes shall be used. ‘The chemical composition shall be as per Table I. Format No. 6-00-000-F1 Rev. 0 Copyright EIL — Allrights reservedSGifotzreT ge ENGINEERS, MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No, sean fore OND LIMITED CARBON STEEL COMPONENTS USED IN 6-79-0012 Rev. 0 * eetamavosamrss” "SOUR SERVICE FOR OIL & GAS Page 6 of 14 PRODUCTION, 4.2.2 Welded Pipes 423 424 425 42.6 API SL Gr. B and API SL Gr.X-52/60 longi welded Table II. | submerged are es shall be used. The chemical composition shall be as per Fittings (Elbow, Tee, Reducer, Cap, Weldolet, Socket, ete.) Seamless fittings shall be ASTM A 234 Gr. WPB. The chemical composition requirements for seamless fittings shall be as per Table 1 Flanges 4.2.4.1 The following product specifications shall be applicable for forged flanges: - ASTM A 105, ASTM. 694 Gr.FS2 API 6A Type 2 API 6A Type 4 The chemical composition shall be as per Table III. 4.2.4.2 All forging shall be normalized in the finished condition, Valves (Ball, Gate, Globe, Check, Needle, etc.) 4.2.5.1 Valve body shall be of forged ASTM 105 or cast ASTM A 216 Gr. WCB. Forgings shall be acceptable in place of castings but not vice versa. All other components of the valve shall be as per the applicable valve data sheet. Chemical composition of forged valves body and of cast valve bodies shall be as per Table III & Table IV respectively. 4.2.5.2 NDT. All valve castings shall be radiographed. The radiographic procedure and the area to be radiographed and the acceptance criteria shall be as per ANSI B 16.34. In addition, Dye Penetrant Testing (DPT) or Magnetic Particle Testing (MPT) shall also be conducted. Plates for Pressure Vessels, Heat Exchangers, Piping and other Process Equipment. 4.2.6.1 Plates shall conform to ASTM A 516 Gr. 60. Maximum UTS & Yield Strength shall not exceed 15 ksi more than the minimum specified values. Format No. &-00-0001-F1 Rev. 0 Copyight EL — Al igh reservedSSAfetz ze gm ENGINEERS, MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No. sBarfelgits SINDALIMTED CARBON STEEL COMPONENTS USED IN 6-79-0012 Rev. 0 il ‘SOUR SERVICE FOR OIL & GAS. Page 7 of 14 PRODUCTION 4.2.6.2. Chemical analysis of plates used in sour service shalll be carried out both on heat and on product as per A 20 and meet the requirements laid own in Table IL 4.2.63 For all thickness of plates either vacuum degassing treatment shall be applied during steel making or through-thickness tensile testing shall be carried out in accordance with ASTM A 770, with the minimum reduction in area being 35% as determined in accordance with ASTM A 370, on one plate per heat per heat-treatment batch. 4 No repair welding shall be permitted on plates. 5 HIC test shall be conducted on one sample per heat per heat treatment batch of plates and other rolled products. 5.0 HARDNESS TEST 5.1 Hardness measurement shall be conducted on products/items/weldments of all materials, E 5.2 Hardness test shall be conducted on a sample of each fi products that do not meet the hardness limits shall be rejected. For small products that cannot be hardness tested individually, the manufacturer shall conduct tests on a random basis on samples selected from production run or stored batches to check the compliance. wed product. The 5.3. The maximum acceptable limit of hardness shall be HRC 22 or equivalent. 6.0 CORROSION TESTS 6.1 Selection of Corrosion Test Samples 6.1.1 Test specimens shall be taken from the finished product. Where the test specimen cannot be extracted from the finished product, a representative test specimen shall be taken from the same heat, 6.1.2 In the case of welded products, the test piece shall include the parent ‘metal, weld metal and the heat affected zones (HAZ). 6.2 Hydrogen Induced Cracking (HIC) Test (Test Duration : 96 Hours) 6.2.1 This test shall be performed on a set of three specimens representing each production batch/heat of rolled products in accordance with NACE TM 0284 with the following acceptance criteria: (i) Crack Length Ratio (CLR) < 10.0% (ii) Crack Sensitivity Ratio (CSR) < 1% Format No, &-00-0007-F1 Rev. 0 Copyight IL — Alright reservedSSIES By ENGINEERS, MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION Wo. SCA WBES@DROALRTID canon steer COMPONENTS Use IN 6-79-0012 Rev. 0 ween ae nce, ‘SOUR SERVICE FOR OIL & GAS Page 8 of 14 PRODUCTION 6.2.2 In case of failure of any one of the specimens, three more specimens from the same product shall be retested and all the specimens shall meet the acceptance criteria. 6.2.3 HIC testing shall be required only for plates or rolled products. This shall be conducted for pre-qualification of the mill and as well as on the batch certification of each heat. 6.2.4 When the fabrication of the components from the previously HIC tested plates involves no heavy wall thickness reduction or material flow, such as bending, spinning or welding, no fresh HIC test would be required on the final product. However, for fabrication of products where heavy reduction of thickness and heavy flow of material encountered while forming such as like forging, extrusion oF drawing, ‘metallographic examination of the final product shall be required to be carried out to ensure absence of elongated inclusions. 62.5 For procurement of small quantity, “off-the-shelf” material, conformance to NACE MR 0175 / ISO 15156 shall be ensured. 63 Sulfide Stress Cracking (SSC) Test 6.3.1 SSC test shall be conducted only for the purpose of pre-qualification of the mills and the welding consumables and not to be used for batch testing. Mill qualification by any reputed third party inspection ageney like Lloyds, BV, CEIL, DNV, EIL or TUV etc., would be acceptable. 6.26 fest shall be conducted as per NACE TM 0177 and shall meet the requirements of NACE MR 0175/ISO 15156. 6.2.7 Mills which have been previously qualified for the supply of materials and welding consumables, shall be permitted to issue the test certificates, which shall be considered acceptable. However, in case of doubt, the owner/purchaser shall get these tests done and shall bear cost of testing, provided such tests meet the requirement. In case the material so retested fails to conform to the requirement, the cost of testing shall be borne by the manufacturer/supplier. 7.0 QUALITY SURVEILLANCE AND INSPECTION DURING PRODUCTION The manufacturers/suppliers shall perform all the tests and inspection: procedures mentioned in this specification, under a third party inspection agency witness to ensure conformance. Company's duly authorized representative shall have unhindered access to the material being subjected to inspection, for witnessing of the ‘sample selection, test specimen preparation and to the performance of tests. Format Ne. 6-00-0001-F1 Rev. 0 ‘Copyight EIL— Alvights reserved_SifereT gy ENGINEERS MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No eames ONT UMITED cay \RBON STEEL COMPONENTS USED IN 6-79-0012 Rev. 0 ee nce wenn ‘SOUR SERVICE FOR OIL. & GAS. Page 9 of 14 PRODUCTION 8.0 QUALIFICATION OF MANUFACTURERS/ SUPPLIERS OF SOUR SERVICE MATERIALS 8.1 82 General All materials for sour service application to this specification shall be supplied only by pre-qualified manufacturers. Whenever the term “Pre-qualified Manufacturer’ appears, it refers only to the manufacturer who is pre-qualified by the company based upon the pre-qualification criteria specified in NACE. MR-0175/ISO-15156. Pre-Qualification Criteria for Vendors with Prior Experience Track Record Vendors/ manufacturers who have proven track record of supplying materials for'onshore/ offshore sour service applications, to any of the reputed operating companies/Engineering Consultants or Process Licensors such as UOP/IFP/EXXON/BP/CHEVRON/IOCL/ HPCL/ BPCL/ EIL/ONGC shall be considered as ‘pre-qualified vendors/manufacturers, on production of the relevant Purchase Orders and test certificates, certified by a witnessing third party inspection agency such as DNV/ Lloyds/ BV/ ABSTECH/ TUV/ SGS/CEIL for the conformance of he materials to the respective materials specification of the mentioned operators/engineering consultants. Pre-Qualification Criteria for New Vendors without Track Record ‘A vendor who has no track record of supplying sour service materials to any of the reputed engineering consultants/operators, as mentioned in Clause 8.2 above, shall be considered as a new vendor and shall be subjected to the elaborate pre-qualification by any one of the reputed third party inspection agencies like Lloyds, BV, CEIL, DNV or TUV ete. as per the requirements of NACE MR-0175/ISO-15156, latest edition. 9.0 SPECIAL REQUIREMENTS FOR WELDING AND FABRICATION FOR SOUR SERVICE ol Welding Procedure Qualification 9.1.1 Each particular welding procedure shall be separately qualified for the job. Previously qualified procedures, if they were qualified under ELL, or a reputed engineering consultant/operator/third party, may be submitted for review and approval. 9.1.2. Welding consumable used shall be of a grade that would produce a weld metal equivalent to the base metal used for the project and shall meet the chemical composition requirements of Table V. 9.1.3 Welding procedure specification shall be prepared by the fabricator! contractor based on the information provided by the suppliers of raw materials and/or the welding consumable manufacturers and shall be Format No, &00-0001-F1 Rev. 0 Copyright EIL— Al ights reservedSie ze aS ENGINEERS. MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No, “eat OAR UMITED CARBON STEEL COMPONENTS USED IN SE hse ‘SOUR SERVICE FOR OIL & GAS. 6-79-0012 Rev. 0 PRODUCTION Page 10 of 14 approved by the company. A maximum heat input of 1.2 kI/mm shall be used during welding procedure qualification testing. 9.2 Welding Consumable Qualification ‘Welding consumable shall conform to a standard classification and of a type and make approved by the company or by any of the reputed third party inspection agencies like Lloyds, BV, CEIL, DNV, TUV, etc. New welding consumables shall be subject t0 qualification testing to check their conformance to the classifications to which they belong. 9.3 The consumable qualification testing shall include all the tests specified by ASME SEC II Part C as well as the SSC tests, chemical composition analysis and hardness testing as per the requirements of this specification. 9.4 Acceptance criteria for mechanical and corrosion tests shall be as those applicable for the base metal. ‘These tests shall be carried out on the undiluted all weld metal. ry The test coupons for the welding procedure qualification shall be extracted from the plates/ pipes having the maximum values of carbon equivalent, maximum inclusion content and maximum thickness, that are intended to be used for the fabrication on the job, 9.6 Tests to be Conducted on PQT 9.6.1 Chemical composition of the weldment shall be carried out to check its conformance to Table V, Microstructural examination at a magnification of 200X shall be conducted to assure complete absence of untempered martensite. 9.6.2. Mechanical tests shall include tensile testing, impact testing and bend testing as per ASME SEC 1X with acceptance criteria as per the governing code of fabrication. Each procedure qualification test sample shall be subjected to detailed hardness survey, with Vickers Hardness Tester, with 5 kg load, of the weld heat affected zone and basemetal in accordance with ASTM standard E-92. The maximum permissible hardness shall be equivalent to RC-22. 9.6.3 Corrosion Tests Only sulfide stress cracking (SSC) test shall be conducted on the procedure qualification test samples as mentioned in clause 6.3, on a sample that contains the weld, parent material and the heat affected zone. Alternatively, a four point bend specimen SSC test for 500 hour, can also be accepted for procedure qualification, Format No, -00-0001-F1 Rev. 0 ‘Copyright EL — Al rights reserved‘SSifetzxe (a ENGINEERS MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No. sar tee OND UMITED CARBON STEEL COMPONENTS USED IN 6-79-0012 Rev. 0 “ener seanrvainmnne "SOUR SERVICE FOR OIL & GAS Page 11 of 14 PRODUCTION 9.6.4 100% Radiographic Examination of the test welds and production welds shall be carried out as per ASME See V, with acceptance criteria as per ASME. SEC VIII Div I, UW-51. 9.6.5 Dye Penetrant or Magnetic Particle testing shall be carried out for the fillet and groove welds, wherever Radiography is not feasible. 9.6.6 Welder Qualification Tests Welders shall be qualified at the fabrication shop/yard/Barge, employing the qualified welding procedures..The welder test specimens shall be subjected to radiographic examination, DPT/MPT and cross- sectional hardness survey, with the same procedures adopted for the PQT and with acceptance criteria mentioned in ASME SEC IX.. 9.6.7 Field Welding Field welding procedure shall be formulated to have a minimum heat input of 1.2 K/min. 9.6.8 Post Weld Heat Treatment All the weld joints irrespective of thickness shall be given a post weld heat treatment. The temperature range for PWHT shall be 595-650°C. Other aspects such as rate of heating , holding time, ete. for the PWHT shall be as per ASME Sec. VIII, Div. / ANSI B31.3 requirements. Format No, &-00-0001-F1 Rev. 0 ‘Copyright EL Alvighs reservedGifetzre am ENGINEERS MATERIAL REQUIREMENTS FOR ‘STANDARD SPECIFICATION No. eaters NIA UMITED cat a folie \RBON STEEL COMPONENTS USED IN 6-79-0012 Rev. 0 " sesuurauvamrs "SOUR SERVICE FOR OIL. & GAS Page 12 of 14 PRODUCTION TABLE-I CHEMICAL COMPOSITION REQUIREMENTS FOR SEAMLE (SOUR SERVICE) A106 Gr. B/ APISL Gr. B PIPES & FITTINGS ELEMENT lr LIMITS mn Ga ale 0.20% max. ~ 0.10%-0.35% ~ 0.01% max 0.02% max. — Note: The unspecified elements Mn. Cu, Ni, Cr, Mo, V ete. shall be as per the limits of A | 106 Gr. B. TABLE ~ II CHEMICAL COMPOSITION REQUIREMENTS FOR PLATES, ROLLED PRODUCTS AND FITTINGS OF CARBON STEEL FOR SOUR SERVICE APPLICATION. (FOR LINE PIPES/PRESSURE VESSELS/HEAT EXCHANGERS/STORAGE VESSELS) ASTM A 516 Gr. 60/A 234 Gr. WPB (Welded)/API SL Gr B(SAW)/API SLXS2/60(SAW) /LEMENT Limits Cc a 0.20% max. Si 0.15% -0.35% 0.003% max. : . P - 0.020% max. | N 0.01% max. | cus 23 a AVN 2min | B 0.002% max. 1. All other unspecified clements like Mn, Cu, Ni, Cr, Mo, V, Nb, Ti, ete. shall be as per ASTM A 516 and ASTM A 20 specifications. Steel shall be produced as HIC resistant steel with inclusion content and morphology control and shall be free of elongated manganese sulfide inclusion. The ratio Ca/S is not applicable when S$ < 0.015%. In such cases, Ca upto 50. | ppm shall be permitted Format No. 8-00-0001-F1 Rev. 0 Copyight EI ~All ight reservedStacie ENGINEERS MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No. sear fellas INDIA LIMITED c/ 2 FHI -ARBON STEEL COMPONENTS USED IN. 6-79-0012 Rev. 0 oe ‘SOUR SERVICE FOR OIL & GAS Page 13 of 14 PRODUCTION TABLE - IL CHEMICAL COMPOSITION REQUIREMENTS FOR FORGED FLANGES (SOUR SERVICE) (ASTM A 105, ASTM A 694 Gr. F52, API 6A (Type 2 & 4) ELEMENT ‘LIMITS : Edens vansvtaréeetetaa | MPansTenTTtTioa ans 0-252 acca s 0.01% max, 0.02% max. Note : All other elements shall be as specified in the basie specification, ‘The forgings shall be produced with inclusion count and morphology control TABLE -IV CHEMICAL COMPOSITION REQUIREMENTS FOR CASTINGS, A216 Gr. WCB ELEMENT ‘LIMITS 0.20% max. 0.10%-0.35% 0.02% max 0.02% max. Note : Alll other unspecified elements shall be as per the basic specification ASTM A216. | | Format No, &-00-0001-F1 Rev. 0 ‘Copyright EIL— Alighis reservedSSiiozTe i ENGINEERS MATERIAL REQUIREMENTS FOR eaters ORD UMITED CARBON STEEL COMPONENTS USED IN ‘SOUR SERVICE FOR OIL & GAS. ‘STANDARD SPECIFICATION No, 6-79-0012 Rov. 0 Page 14 of 14 PRODUCTION TABLE-V CHEMICAL COMPOSITION REQUIREMENTS FOR WELDING CONSUMABLES LIMITS 0.15 % max. Mn 0.40% max, P 0.020% max s 0.012% max. Cr+Mo I 0.50 % max. ~ : NitCu : : | 0.20 % max Ni 0.20% max. 7 - Si As per AWS specification. ce 0.40 max. Format No. 6-00-0001-F} Rev. 0 Copyright EL ~Alrights reserved